Metal-zeolite compositions prepared by mechanochemical synthesis, and methods of use

Abstract

A metal-zeolite composition comprising: (i) a zeolite phase; and (ii) a metal, other than aluminum or silicon, nanoscopically dispersed throughout said zeolite phase, wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 1 micron, wherein the zeolite may be, for example, a dealuminated zeolite, and the metal may be selected from transition metals, main group metals, and lanthanide metals. Also described herein is a method for producing the metal-zeolite composition in which a zeolite phase and metal salt are mixed and ground by a solvent-less ball milling process to produce an initial mixture, and calcining the initial mixture to produce the metal-zeolite composition. Further described herein is a method for converting an oxygen-containing organic species to a hydrocarbon, the method comprising contacting the species with the above described metal-loaded zeolite catalyst at a temperature of at least 100° C. and up to 550° C.

What is claimed is: 
     
         1 . A metal-zeolite composition comprising:
 (i) a zeolite phase; and   (ii) a metal, other than aluminum or silicon, nanoscopically dispersed throughout said zeolite phase, wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 1 micron.   
     
     
         2 . The composition of  claim 1 , wherein said zeolite phase is a dealuminated zeolite phase. 
     
     
         3 . The composition of  claim 1 , wherein said zeolite phase is a ZSM-5 zeolite phase. 
     
     
         4 . The composition of  claim 1 , wherein said metal is selected from transition metals. 
     
     
         5 . The composition of  claim 1 , wherein said metal is selected from main group metals. 
     
     
         6 . The composition of  claim 1 , wherein said metal is selected from lanthanide metals. 
     
     
         7 . The composition of  claim 1 , wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 0.5 micron. 
     
     
         8 . The composition of  claim 1 , wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 0.1 micron. 
     
     
         9 . The composition of  claim 1 , wherein agglomerations of said metal are not present, and said metal is atomically dispersed throughout said zeolite phase. 
     
     
         10 . The composition of  claim 1 , wherein the metal-zeolite composition is produced by a process in which said zeolite phase and a metal salt containing said metal are intimately mixed and ground in a solvent-less ball milling process followed by calcination. 
     
     
         11 . The composition of  claim 10 , wherein said ball milling process employs a speed of at least 150 rpm for at least 5 minutes. 
     
     
         12 . The composition of  claim 10 , wherein said ball milling process employs a speed of at least 200 rpm for at least 5 minutes. 
     
     
         13 . The composition of  claim 10 , wherein said calcination is conducted at a temperature of at least 400° C. for at least 3 hours. 
     
     
         14 . A method for producing a metal-zeolite composition, the method comprising:
 (i) mixing and grinding a zeolite phase and a metal salt by a solvent-less ball milling process to produce an initial mixture; and   (ii) calcining said initial mixture to produce said metal-zeolite composition, wherein the metal in said metal-zeolite composition is nanoscopically dispersed throughout said zeolite phase, wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 1 micron.   
     
     
         15 . The method of  claim 14 , where said zeolite phase is a dealuminated zeolite phase. 
     
     
         16 . The method of  claim 14 , wherein said zeolite phase is a ZSM-5 zeolite phase. 
     
     
         17 . The method of  claim 14 , wherein said metal is selected from transition metals. 
     
     
         18 . The method of  claim 14 , wherein said metal is selected from main group metals. 
     
     
         19 . The method of  claim 14 , wherein said metal is selected from lanthanide metals. 
     
     
         20 . The method of  claim 14 , wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 0.5 micron. 
     
     
         21 . The method of  claim 14 , wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 0.1 micron. 
     
     
         22 . The method of  claim 14 , wherein agglomerations of said metal are not present, and said metal is atomically dispersed throughout said zeolite phase. 
     
     
         23 . The method of  claim 14 , wherein said solvent-less ball milling process employs a speed of at least 150 rpm for at least 5 minutes. 
     
     
         24 . A method for converting an oxygen-containing organic species into a hydrocarbon fraction, the method comprising contacting the oxygen-containing organic species with a metal-containing zeolite catalyst at a temperature of at least 100° C. and up to 550° C. to result in said oxygen-containing organic species being converted to said hydrocarbon fraction, wherein said metal-containing zeolite catalyst comprises the following components:
 (i) a zeolite phase; and 
 (ii) a metal, other than aluminum or silicon, nanoscopically dispersed throughout said zeolite phase, wherein, if agglomerations of said metal are present, the agglomerations have a size of no more than 1 micron. 
 
     
     
         25 . The method of  claim 24 , wherein said zeolite phase is dealuminated. 
     
     
         26 . The method of  claim 24 , wherein the zeolite phase is a ZSM-5 zeolite phase. 
     
     
         27 . The method of  claim 24 , wherein the metal is selected from the group consisting of copper, zinc, iron, lanthanide metals, and combinations thereof.